Partially Opaque-Partially Clear Laminate Tubes and Methods

ABSTRACT

The present relates a laminate comprising: an outer polyethylene (PE) layer; a first adhesive layer; a substrate layer with one side selectively vacuum metalized or selectively reverse printed and said printed or metalized side is toward first adhesive layer; a second adhesive layer; an ethylene vinyl alcohol (EVOH) polymer barrier film layer; an linear density polyethylene (LDPE) extrusion layer; and an inner polyethylene (PE) layer. The present disclosure further relates to tubes made of the partially opaque and partially clear laminate. The present disclosure also relates to a process of manufacturing of tubes using the said laminate.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a division of U.S. application Ser. No.14/125,531, filed Dec. 11, 2013, which is a National Stage ofInternational Application No. PCT/IN2012/000421, filed Jun. 14, 2012,which claims priority to Indian Application No. 1732/MUM/2011 filed Jun.14, 2011, the contents of which are hereby incorporated by reference intheir entireties.

TECHNICAL FIELD

The present disclosure relates to a partially opaque and partially clearlaminate; and a tube made of such laminate.

The present disclosure also relates to a process for manufacturing ofsuch laminate tubes.

BACKGROUND

Gravure printing is a process known for quite some time. The basicconcepts of gravure printing are known in ancient Italy and China. InChina, it is said to have evolved from 100 AD, where printing plateswere prepared by hand using engraving tools. In the 16.sup.th centurywith the invention of etching using chemicals, scratching of images as aresistant coating on the surface of metal printing plate was known. Withthe advent of photography in the late 19.sup.th century, the challengeof reproducing images that are near to real world posed the printingindustry. This was when gravure was able to duplicate the photographicfilms by using gelatin, which hardened when exposed to light. Theunhardened areas were washed away and etched using acid. These paved wayfor gravure printing techniques that are widely used today.

Gravure printing is vastly used in various industries including that ofpackaging. By using this technique many packaging products are made.Further, plastic tubes form an integral part of the packaging industryas they are used to enhance the shelf-life of packaged goods and createa unique product identity. Laminated Tubes are used for packaging invarious sectors like oral care, food, cosmetics, pharmaceuticals, andalso for other industrial applications. The oral care industrycontributes to 70% of production of laminated tubes. The laminated tubesthus made are of two types, viz. Aluminum Barrier Laminates (ABL) tubesthat have an aluminum foil barrier, which provides superior light, airand moisture barrier along with reduced flavor absorption. The materialdensity offers a more durable tube and allows for additional dispensingof the products contents. Pastes, ointments, cream and gels typicallydentifrice, over-the-counter and pharmaceutical products fare well inAluminum Barrier Laminates (ABL) tube packaging. The second type oflaminated tubes is Plastic Barrier Laminates (PBL) tubes that possessstructures that are a good option for packaging with a need to maintainits form and shape. It presents a more cosmetic look and isenvironmental friendly. Special barriers can be provided such asEthylene Vinyl Alcohol Polymer (EVOH), Nylon to offer a strong chemicalresistance. Standard material is offered in white or natural (clear) butspecialty custom colors can also be developed.

U.S. Pat. No. 6,041,929 discloses a film bag with hidden indicia formedin the film bag laminate, which is not viewed from outside the package.GB Patent 2,338,679 discloses a substrate for security documents such asbanknotes, cheques, passports, etc. U.S. Pat. No. 5,443,915 discloses anoriented polyolefinic laminated film which has a core, a TiO2 containingwhite partially cold seal receptive polyolefinic skin layer on one sideof the core, and a vacuum metalized surface on the other side of thecore. US Patent application 2006/01519993 discloses a laminated securitydocuments or tokens and process for manufacturing the same.

Plastic barrier layer (PBL) laminate tubes are also made of thepolymers, but the barrier layer is made of a polymeric material, EthylVinyl alcohol (EVOH) or Nylon. The Plastic barrier layer (PBL) laminatedtubes are widely used in applications requiring attractive packagingsuch as for cosmetic products, good resilience (ability of tubes toreturn to their original shape after squeezing), and attractive visualand tactile effects. The Plastic barrier layer (PBL) laminated tubes areemerging as an alternative to aluminum foil based tubes.

The structure of the Plastic barrier layer (PBL) laminated tube known inthe state-of-the-art comprises a polyethylene (PE) white layer as anouter layer. It has two layers of polyethylene (PE) encompassing acentral layer of ethylene vinyl alcohol (EVOH), which acts as a barrierbetween the polyethylene (PE) layers. Finally it has an outer layerfacing the product of polyethylene (PE). The laminates, which can betailor-made, are either made transparent/clear or opaque or colored.Generally, the master batch consists of one form of laminates, i.e.transparent, opaque or colored.

SUMMARY

The present disclosure relates to a partially opaque and partially clearlaminate.

In an aspect of the present disclosure, it provides a partially opaqueand partially clear laminate comprising an outer polyethylene (PE)layer; a first adhesive layer; a substrate layer with one sideselectively vacuum metalized or selectively reverse printed and saidprinted or metalized side is toward first adhesive layer; a secondadhesive layer; an ethylene vinyl alcohol (EVOH) polymer barrier filmlayer; a low density polyethylene (LDPE) extrusion layer; and an innerpolyethylene (PE) layer.

The present disclosure further relates to tubes made of the partiallyopaque and partially clear laminate.

The present disclosure also relates to a process of manufacturing thelaminate tube from the partially opaque and partially clear laminate.

These and other features, aspects, and advantages of the present subjectmatter will be better understood with reference to the followingdescription. This summary is provided to introduce a selection ofconcepts in a simplified form. This summary is not intended to identifykey features or essential features of the disclosed subject matter, noris it intended to be used to limit the scope of the disclosed subjectmatter.

BRIEF DESCRIPTION OF DRAWINGS

The above and other features, aspects, and advantages of the subjectmatter will be better understood with regard to the followingdescription, appended claims, and accompanying drawings where:

FIG. 1 illustrates a structure of a partially opaque and a partiallyclear laminate, according to an embodiment of the present subjectmatter.

FIG. 2 illustrates a flow diagram of manufacturing process of apartially opaque and a partially clear tube, according to an embodimentof the present subject matter.

DETAILED DESCRIPTION

The present disclosure provides a laminate which is partially opaque andpartially clear and tubes formed thereof.

In one aspect, an embodiment of the present disclosure provides thepartially opaque and partially clear laminate comprising: an outerpolyethylene (PE) layer; a first adhesive layer; a substrate layer withone side selectively vacuum metalized or selectively reverse printed andsaid printed or metalized side is toward first adhesive layer; a secondadhesive layer; an ethylene vinyl alcohol (EVOH) polymer barrier filmlayer; a low density polyethylene (LDPE) extrusion layer; and an innerpolyethylene (PE) layer.

In an embodiment, the outer polyethylene (PE) layer of the partiallyopaque and partially clear laminate, is a three layer film comprising:48.0%-48.5% metallocene linear low density polyethylene (LLDPE);48.0%-48.5% linear density polyethylene (LDPE); and 3.0%-4.0% of aClarifier in all the three layers. The layer ratio is 1:2:1 or 1:1:1 togive extra clear film. The clarifier can be any of the notablycommercially available one such as “clariant”, “Ambasad”, “Millikon”.

The outer polyethylene (PE) film layer can also be optionally printed bysurface printing techniques. According an embodiment of the presentdisclosure provides a laminate wherein the outer polyethylene (PE) filmlayer is surface printed.

In another embodiment, the substrate layer on one side of which isselectively vacuum metalized or selectively reverse printed, can beselected from Polyethylene terephthalate polymer (PET), nylon, biaxiallyoriented film (BOPP) or Polyethylene (PE). The substrate layer isreverse printed or can be selectively printed, i.e. wherever, thelaminate has to be opaque, can be printed. The remaining portion of thelaminate is left clear. The laminate tubes made of such laminate inaccordance with the present disclosure can be used for a variety ofapplications, requiring in aesthetic values, for packaging such as forcosmetic products, good resilience (ability of tubes to return to theiroriginal shape after squeezing), and attractive visual and tactileeffects.

In an aspect of the present disclosure, the laminate can be printedopaque half way by reverse printing and left clear for the other half,such that, selectively opaque parts in the laminate can be obtained,which are alternate opaque and alternate clear. This can be bothhorizontal and vertical depending upon the customer needs. The reverseprinting technique used in the present disclosure is Gravure printing.Generally, reverse printing is generally used when the decoration of theproduct is viewed through the carrier layer. To protect the decoration,for example against wear and tear it is performed to use reverseprinting method.

In a gravure printing process, the image is printed on the reverse orthe inner side of the outer substrate i.e. the print layer. Gravure is abig cylinder, which is used in flexible packaging of materials. It ismade by engraving or etching on a steel or copper base in a preferredembodiment. In this technology, the gravure cylinder is configured insuch a way that it can be selectively printed. Though, it is possible toprint only on the surface of the laminate, such that a particular patchof the laminate can be color printed or white effect printed, it isstill desirable to have selectively opaque parts in the laminate byusing gravure printing.

In another aspect, the partially opaque and partially clear laminatecomprising of a substrate layer, selected from Polyethyleneterephthalate (PET), nylon, biaxially oriented film (BOPP), orPolyethylene (PE) wherein one side of said substrate layer is reverseprinted by gravure reverse printing process, or metallized by vacuummetallization. The printed or metallized substrate is then placedbetween two adhesive layers. The printed or the metallized side islaminated with a clear Polyethylene (PE) film, which can be furthersurface printed. The non-printed or non-metallized side of the substratelayer is then laminated with an ethylene vinyl alcohol (EVOH) polymerbased barrier film. The ethylene vinyl alcohol (EVOH) polymer based filmis in contact with a Low density polyethylene (LDPE) extrusion layer.The low density polyethylene (LDPE) layer is followed by a polyethylene(PE) film layer that acts as a sealant layer. Thus a partially opaqueand partially clear laminate is formed, which is further slitted torequired length of tubes.

The first adhesive layer and the second adhesive layer in accordancewith the present invention may be same or different. In one aspect, thefirst adhesive layer and the second primer layer are same. In anotheraspect, the adhesive layers independently, can be selected from any ofthe high performance adhesives from Henkel like Liofol UR 2790/UR5026-21or Liofol 3644/Hardener 6055 or any other high performance adhesivewhich can give good bond against aggressive product formulations. Theadhesive layer when present in the laminate of the present disclosurecan be of thickness ranging from 5μ to 7μ.

In yet another embodiment, the ethylene vinyl alcohol (EVOH) polymerfilm layer is a five or a seven layered film layer. In accordance withthe present disclosure, the ethylene vinyl alcohol (EVOH) film layercomprises a core ethylene vinyl alcohol (EVOH) polymer layer between twoadhesive layers, further sandwiched by polyethylene (PE) layers.

In an aspect, the five-layered ethylene vinyl alcohol (EVOH) layercomprising: a polyethylene layer of linear low density polyethylene(LLDPE) and low density polyethylene (LDPE) having a thickness in therange of 15μ-30μ; a first tie layer having a thickness in the range of8μ-20μ; an ethylene vinyl alcohol (EVOH) polymer layer having athickness in the range of 5μ-25μ; a second tie layer having a thicknessin the range of 8μ-20μ; and a polyethylene layer of linear low densitypolyethylene (LLDPE) and low density polyethylene (LDPE) having athickness in the range of 10μ-30μ.

In an preferred embodiment, the five-layered ethylene vinyl alcohol(EVOH) layer comprises: a polyethylene layer of linear low densitypolyethylene (LLDPE) and low density polyethylene (LDPE) having acombined thickness of 20μ; a first tie layer having a thickness of 12μ;an ethylene vinyl alcohol (EVOH) polymer layer having a thickness of15μ; a second tie layer having a thickness of 12μ; and a polyethylenelayer of linear low density polyethylene (LLDPE) and low densitypolyethylene (LDPE) having a combined thickness of 20μ.

The structure of the above five layered structure is depicted as:

20μ ((Linear low density polyethylene (LLDPE)+Low density polyethylene(LDPE))//12μ First Tie layer//15μ, Ethylene vinyl alcohol (EVOH)//12μSecond Tie layer//20μ, (Linear low density polyethylene (LLDPE)+Lowdensity polyethylene (LDPE)).

In an aspect, the seven-layered ethylene vinyl alcohol (EVOH) layercomprising: a polyethylene layer of linear low density polyethylene(LLDPE) and low density polyethylene (LDPE) having a thickness in therange of 15μ-30μ; a first tie layer having a thickness in the range of8μ-20μ; a first ethylene vinyl alcohol (EVOH) polymer layer having athickness in the range of 4μ-6μ; a nylon 6 layer having a thickness inthe range of 4μ-6μ; a second ethylene vinyl alcohol (EVOH) polymer layerhaving a thickness in the range of 4μ-6μ, a second tie layer having athickness in the range of 8μ-20μ; and a polyethylene layer of linear lowdensity polyethylene (LLDPE) and low density polyethylene (LDPE) havinga thickness in the range of 10μ-30μ.

In an preferred embodiment, the seven-layered ethylene vinyl alcohol(EVOH) layer comprises: a polyethylene layer of linear low densitypolyethylene (LLDPE) and low density polyethylene (LDPE) having acombined thickness of 20μ; a first tie layer having a thickness of 12μ;a first ethylene vinyl alcohol (EVOH) polymer layer having a thicknessof 5μ; a nylon 6 layer having a thickness of 5μ; a second ethylene vinylalcohol (EVOH) polymer layer having a thickness of 5μ; a second tielayer having a thickness of 12μ; and a polyethylene layer of linear lowdensity polyethylene (LLDPE) and low density polyethylene (LDPE) havinga combined thickness of 20μ.

The structure of the above seven layered structure is depicted as:

20μ ((Linear low density polyethylene (LLDPE)+Low density polyethylene(LDPE))//12μ First Tie layer/5μ First ethylene vinyl alcohol (EVOH)//5μNylon 6//5μ Second ethylene vinyl alcohol (EVOH)//12μ Second Tielayer//20μ (Linear low density polyethylene (LLDPE)+Low densitypolyethylene (LDPE)).

In accordance with the present disclosure, the total thickness ofethylene vinyl alcohol (EVOH) polymer film layer is 70μ-90μ, preferably79μ.

The laminate structure or the arrangement of the layers in the laminatestructure, in accordance with the present disclosure, facilitates twotypes of printing in the partially opaque and partially clear laminate.The first printing is the selective metallization or printing in thesubstrate layer and the second printing is on the top polyethylenelayer. The specific arrangement of the different layers in the laminatefacilitates in obtaining a tube made of such laminate.

In accordance with the present disclosure, the term “opaque” refers tocolored, printed, metallized or translucent portion of the laminate. Theterm “clear” refers to transparent, see-through, or limpid portion ofthe laminate.

In another embodiment, the inner polyethylene (PE) layer is a threelayer film or a mono layer film.

In another aspect, an embodiment of the present disclosure provides apartially opaque and partially clear laminate comprising: an outerpolyethylene (PE) layer having a thickness of 70μ-100μ; a first adhesivelayer having a thickness of 5μ-7μ; a substrate layer with one sideselectively vacuum metalized or selectively reverse printed and saidprinted or metalized side is toward said outer polyethylene layer havinga thickness of 10μ-12μ; a second adhesive layer having a thickness of5μ-7μ; an ethylene vinyl alcohol (EVOH) polymer barrier film layerhaving a thickness of 79μ-90μ; a low density polyethylene (LDPE)extrusion layer having a thickness of 20μ-65μ; and an inner polyethylene(PE) layer having a thickness of 70μ-120μ.

In a preferred embodiment, the partially opaque and partially clearlaminate comprising: an outer polyethylene (PE) layer having a thicknessof 70μ; a first adhesive layer having a thickness of 5μ-6μ a substratelayer with one side selectively vacuum metalized or selectively reverseprinted and said printed or metalized side is toward said outerpolyethylene layer having a thickness of 10μ-12μ second adhesive layerhaving a thickness of 5μ-6μ; an ethylene vinyl alcohol (EVOH) polymerbarrier film layer having a thickness of 79μ; a linear densitypolyethylene (LDPE) extrusion layer having a thickness of 20μ; and aninner polyethylene (PE) layer having a thickness of 100μ.

The laminate of the present disclosure can be of thickness in the rangeof 250μto 400μ.

In one embodiment, the partially opaque and partially clear laminate, inaccordance with the present disclosure, is used in manufacturing oflaminate tube. In case of tube processes, extrusion lamination ispreferably used.

The present disclosure further provides a process of manufacturing thelaminate tube from said laminate comprising: providing the substratelayer; selectively gravure printing or vacuum metalized to the substratelayer using a suitable ink; applying adhesive lamination on both sidesof the substrate layer; coating the substrate layer with ethylene vinylalcohol (EVOH) barrier film; coating print side of the substrate layerwith polyethylene (PE) film; extruding polyethylene (PE) film byextrusion lamination; coating the product facing side with polyethylene(PE) film; forming a partially opaque and a partially clear laminate;slitting rolls of partially opaque and a partially clear laminate byslitting process; printing of the rolls; and forming a partially opaqueand a partially clear laminated tubes by tubing process.

The substrate layer used in the process above is selected frompolyethylene terephthalate (PET) polymer, nylon, biaxially oriented film(BOPP), or Polyethylene (PE).

In an embodiment, the above process involves surface printing of thepolyethylene (PE) film that forms the outer layer of the laminate.

In an embodiment, FIG. 1 provides an exemplary presentation of thepartially opaque and partially clear laminate of the present disclosure.FIG. 1 shows a structure of partially opaque and partially clearlaminate 100 in accordance to a preferred embodiment of the presentdisclosure. The partially opaque and clear laminate structure 100comprises a layer of 70μ clear film in accordance to an aspect of thepresent disclosure. This acts as an outer print layer 102-1. The clearfilm layer 102-1 in a preferred embodiment is formed of polyethylene. Inan aspect of the present disclosure, there can be more than one layer ofpolyethylene (PE), and most preferably three layers of polyethylene (PE)that acts as a clear film layer 102-1. A top adhesive layer 104-1 of 5to 6 g/m² follows the clear film layer. The top adhesive layer 104-1serves as the binding layer between the outer clear film layer 102-1 andthe next layer underneath the top adhesive layer 104-1. Selected basedon the composition of the outer layer and the next layer, the topadhesive layer can be a cold solvent based or solvent less adhesive orany ready made adhesive known in the state-of-the-art. The gravure printlayer or vacuum metalized layer 106 is formed for about 10μ to 12μbeneath the top adhesive laminate layer 104-1. This substrate layer isformed of polyethylene terephthalate (PET), nylon, biaxially-orientedpolypropylene (BOPP) or Polyethylene (PE) layer. Polyethyleneterephthalate (PET) shows enhanced tear strength and elongationproperties. In an alternative embodiment, this can be a clear ormetallized biaxially-oriented polypropylene (BOPP) or a reverse printednylon layer. The above process provides a 10μ to 12μ inner printed layer106, which is an integral part of the laminate 100. This in addition tothe 70μ outer clear film 102-1 that is available for surface printingprovides an adhesive laminate with an outer and inner printingcapability. Underneath the reverse printed polymer layer 106, a bottomadhesive layer 104-2 is provided for a similar thickness as that of thetop adhesive layer 104-1, i.e. 5 to 6 g/m². The bottom adhesive layer104-2 serves as the binding layer between the gravure print layer 106and the next layer underneath the bottom adhesive layer 104-2.

In a preferred embodiment, underneath the bottom adhesive layer 104-2,the laminate 100 comprises 5 or 7 layers of barrier film 108 of 79μthickness. The barrier layer 108 is also referred to as a core layer.The barrier layer 108 serves as a barrier to either air/oxygen ormoisture or both. The barrier layer can be formed of aluminum orethylene vinyl alcohol (EVOH). The aluminum barrier layer provideseffective barrier properties against atmospheric gases, while theethylene vinyl alcohol (EVOH) is employed to provide barrier against airas well as moisture and also exhibits good aroma-preservation property.In a preferred embodiment of the present disclosure, ethylene vinylalcohol (EVOH) based barrier film 108 of 79μ thickness is employed. Theuse of ethylene vinyl alcohol (EVOH) based barrier film 108 makes thelaminate 100 of the present subject matter a plastic barrier laminate(PBL).

The barrier film layer 108 is followed by a low density polyethylene(LDPE) extrusion layer 110, which in a preferred embodiment is of 20μthickness. The low density polyethylene (LDPE) used in the presentdisclosure is advantageously of density around 0.918 g/cc to 0.935 g/cc,preferably 0.933 gm/cc and the density of the linear low densitypolyethylene (LLDPE) used is advantageously around 0.918 g/cc to 0.940g/cc, preferably 0.927 gm/cc. Underneath the low density polyethylene(LDPE) layer 110, a clear film layer 102-2 of polyethylene (PE) thatcontacts the product is provided. In a preferred embodiment, threelayers of clear film 102-2 of polyethylene (PE) can be advantageouslyprovided, which is of 100μ thickness. The nature of this polyethylene(PE) layer 102-2 is such that, it acts as a product contact layer.Further it also acts as a sealant layer due to the efficient sealingcharacteristics of polyethylene (PE).

In an embodiment, FIG. 2 is an exemplary presentation of a manufacturingprocess 200 of a laminate tube by using the partially opaque andpartially clear laminate of the present disclosure. The process 200involves advantageously selecting 202 10μ to 12μ of polyethyleneterephthalate (PET), biaxially oriented film (BOPP), Nylon film orPolyethylene (PE) in an aspect of the present disclosure. The selected202 polyethylene terephthalate (PET) or biaxially oriented film (BOPP)film is gravure reverse printed or vacuum metallized 204, which isadvantageously engraved on its surface and an ink bath, which is aliquid ink of advantageous properties. The liquid ink is selectivelymetallized by adding glossy silver. The reverse printed or metallizedsubstrate 204 that can be polyethylene terephthalate (PET), nylon orbiaxially oriented film (BOPP) film is then adhesive laminated 206 onboth sides. The above process 200 advantageously involves reverseprinting or vacuum metallization 204 on polyethylene terephthalate(PET), nylon or biaxially oriented film (BOPP) film prior to adhesivelamination 206, which is not the case with the conventionally availabletechniques for making laminate tubes. The substrate side of the adhesivelaminated film is coated 208 with a barrier film, preferably an ethylenevinyl alcohol (EVOH) based barrier film of 79μ, while the other side orthe print side of the film is advantageously coated 210 with a 70μ,layer of polyethylene (PE) clear film. Upon coating 208, 210 both sidesof the film with the barrier film and clear film respectively, thepolyethylene (PE) layer is now extruded 212 by normal extrusionlamination process, which is further laminated 214 with a 100μpolyethylene (PE) layer on the product contact side to advantageouslyform 216 a 280μ partially opaque and clear laminate. The extrusionlamination process 212 ensures that the heat resistant ink on thesurface of the film is not removed. In an alternative embodiment, thepartially opaque and clear laminate can be advantageously formed in arange of 200μ to 400μ. The partially opaque and clear continuouslaminate thus formed 216 is slitted 218 into required length by passingthrough a blade that slits the laminate according to the size of thetube to be manufactured. Finally the laminate tubes are formed by atubing process 222.

In a preferred embodiment, the above process involves surface printing220 of the laminates thus formed. This is enabled by the gravureprinting done on the reverse side of the laminate or the selectivevacuum metallization process. Thus, the laminate 100 can be surfaceprinted 220 and reverse printed 204 through its length. This providesthe required opaque, colored, and clear effect on the plastic barrierlaminate (PBL) tubes formed by the tubing step at the end of themanufacturing process.

There are various advantageous associated with the above described innerprinting process. They are not subjected to color fading, scratches, andany other wear and tear that are associated with outer surface printing.The printing ink that is used in case of inner printing is differentfrom that of the outer printing ink. Generally, in case of outerprinting, solid inks are used. UV ink is most often used, as it does notrequire any solvent. However, in case of inner printing, liquid ink isused with a solvent. In a preferred embodiment, the solvent can beacetone, whose viscosity is as good as that of water. In an aspect ofthe present invention, the liquid ink comprises at least one binder, asolvent or a mixture of plurality of solvents, a plurality of colorantsand additives. Further, the inner printing provides leverage forobtaining any desired pattern. This is mainly due to the reason thatprinting inside means that the laminate can still be printed outsideduring the regular laminate process. Therefore, one can achieve a numberof combinations of patterns by this process. Moreover inner ink printingensures that it can be further laminated and printed. This also ensuresthat the end portion of a tube laminate can be kept opaque.

The gravure printing process can also be surface printing in anotheraspect of the invention. The inner printing process provides variationof printed layers through the depth of a laminate. On the other hand,the gravure printing on the outer surface provides the alternateportions of white, color and opaque printed on the surface withoutvariation in depth. Therefore, it is preferable to have the gravureprint as part of laminate than as part of outer surface.

The gravure cylinder is etched in such a manner that it resists any sortof image breakdown during the rotation of the cylinder, especially incase of laminate of lesser thickness. Before printing, the gravurecylinders are heated in warm water and cleaned in order to remove anyimpurities from the surface of the cylinder. This process cures thepresence of solvent on the surface of the cylinder. The clean cylindersare then chrome plated before the printing process. The gravure cylinderis then made to rotate by immersing on a liquid ink bath. On immersing,the channels on the surface of the gravure cylinder are filled with theliquid ink. An intermediately located doctor blade wipes off any surplusink on the surface of the gravure cylinder. This ensures that therotating gravure cylinder carries ink in its channels only. There isanother roller called an impression roller that counteracts on the otherside of the laminate that is passed, whose one side is in contact withthe gravure cylinder. The impression cylinder enables proper transfer ofink into the gravure print layer of the laminate. The quantity of liquidink carried through the channels of the gravure cylinder may depend onvarious factors including the selection of transparent, colored, andopaque surfaces on the tube laminate, the kind of polymer used in thegravure print layer of the laminate, the target application of the tubelaminate being extruded and so on. The thickness or the depth of thechannels in the gravure cylinder is proportional to the intensity oftone produced on the gravure print layer. This ensures that at areaswhere there is a need for a clear or transparent layer, the thickness ofthe channels can be selected to be at a minimum so that either no ink orless quantity of ink is carried through. Similarly, at areas within thelaminate where there is a need for a colored or an opaque layer, thethickness of the channels can be selected to be at a maximum, so thatstronger tone of ink is achieved on such areas. The adhesive laminationthus obtained is not dependent on temperature. This ensures that the inkis not removed during the process of lamination. In another aspect ofthe invention, selectively metallized PET can form a gravure printlayer. In this case, the liquid ink used for inner printing on thegravure print layer is made of glossy silver inks, which gives theeffect of metallization to the polyethylene terephthalate (PET) layer.This provides a glossy finish to the laminate tubes thus made.

EXAMPLES

The disclosure will now be illustrated with working examples, which isintended to illustrate the working of the disclosure and not intended totake restrictively to imply any limitations on the scope of the presentdisclosure. Other embodiments are also possible.

Example 1

An outer polyethylene (PE) layer is in contact with a first adhesivelayer. The first adhesive layer binds to a substrate layer with one sideselectively vacuum metalized or selectively reverse printed. Thesubstrate layer is in contact with a second adhesive layer. The secondadhesive layer is in contact with an ethylene vinyl alcohol (EVOH)polymer barrier film layer. The inner polyethylene (PE) layer is incontact with the above barrier layer.

Example 2

A three layered outer polyethylene (PE) layer of 48.0%-48.5% metallocenelinear low density polyethylene (LLDPE); 48.0%-48.5% low densitypolyethylene (LDPE); and 3.0%-4.0% of a clarifier is in contact with afirst adhesive layer. The first adhesive layer binds to a substratelayer with one side selectively vacuum metalized or selectively reverseprinted. The substrate layer is in contact with a second adhesive layer.The second adhesive layer is in contact with an ethylene vinyl alcohol(EVOH) polymer barrier film layer. The inner polyethylene (PE) layer isin contact with the above barrier layer.

Example 3

A partially opaque and a partially clear laminate is prepared in thesame way as outlined in example 2, having the laminate structure:

A three layered outer polyethylene (PE) layer of 48.2% metallocenelinear low density polyethylene (LLDPE); 48.3% low-density polyethylene(LDPE); and 3.5% of a clarifier is in contact with a first adhesivelayer//a substrate layer having a thickness of 11μ//an second adhesivelayer having a thickness of 6μ//barrier film layer of ethylene vinylalcohol (EVOH) having a thickness of 79μ/extrusion layer of linear lowdensity polyethylene (LLDPE) having a thickness of 20μ//innerpolyethylene (PE) layer having a thickness of 100μ.

Example 4

An outer polyethylene (PE) layer having a thickness in the range of70μ-100μ is in contact with a first adhesive layer having a thickness inthe range of 5μ-7μ. The first adhesive layer binds to a substrate layerwith one side selectively vacuum metalized or selectively reverseprinted having a thickness in the range of 10μ-12μ. The substrate layeris in contact with a second adhesive layer having a thickness in therange of 5μ-7μ. The second adhesive layer is in contact with a barrierlayer of ethylene vinyl alcohol (EVOH) having a thickness in the rangeof 79μ-90μ. This barrier layer binds with a extrusion layer of linearlow density polyethylene (LLDPE) having a thickness in the range of20μ-65μ. The inner polyethylene (PE) layer having a thickness in therange of 70μ-120μ is in contact with the above extrusion layer.

Example 5

A partially opaque and a partially clear laminate is prepared in thesame way as outlined in example 2, having the laminate structure:

An outer polyethylene (PE) layer having a thickness of 70μ//firstadhesive layer having a thickness of 6μ//a substrate layer having athickness of 11μ//an second adhesive layer having a thickness of6μ//barrier film layer of ethylene vinyl alcohol (EVOH) having athickness of 79μ//extrusion layer of linear low density polyethylene(LLDPE) having a thickness of 20μ//inner polyethylene (PE) layer havinga thickness of 100μ.

Example 6

The five-layered ethylene vinyl alcohol (EVOH) film layer is prepared.The total thickness of the five-layered ethylene vinyl alcohol (EVOH)film layer is 70μ-90μ. A polyethylene layer of linear low densitypolyethylene (LLDPE) and low density polyethylene (LDPE) having athickness in the range of 15μ-30μ is in contact with a first tie layerhaving a thickness in the range of 8μ-20μ which in turn is bound to anethylene vinyl alcohol (EVOH) polymer layer having a thickness in therange of 5μ-25μ. A second tie layer having a thickness in the range of8μ-20μ is in contact with the polymer layer. A polyethylene layer oflinear low density polyethylene (LLDPE) and low density polyethylene(LDPE) having a thickness in the range of 10μ-30μ is in contact with theabove second tie layer.

Example 7

The five-layered ethylene vinyl alcohol (EVOH) film layer is prepared inthe same way as outlined in example 6, having the laminate structure:

20μ ((Linear low density polyethylene (LLDPE)+Low density polyethylene(LDPE))/12μ Tie layer/15μ Ethylene vinyl alcohol (EVOH)/12μ Tielayer/20μ ((Linear low density polyethylene (LLDPE)+Low densitypolyethylene (LDPE)).

The total thickness of the five-layered ethylene vinyl alcohol (EVOH)film layer is 79μ.

Example 8

The seven-layered ethylene vinyl alcohol (EVOH) film layer is prepared.The total thickness of the five-layered ethylene vinyl alcohol (EVOH)film layer is 70μ-90μ. A polyethylene layer of linear low densitypolyethylene (LLDPE) and low density polyethylene (LDPE) having athickness in the range of 15μ-30μ is, in contact with a first tie layerhaving a thickness in the range of 8μ-20μ which in turn is bound to afirst ethylene vinyl alcohol (EVOH) polymer layer having a thickness inthe range of 4μ-6μ. The first ethylene vinyl alcohol (EVOH) polymerlayer is in contact with a nylon 6 layer having a thickness in the rangeof 4μ-6μ. This nylon 6 layer is bound to a second ethylene vinyl alcohol(EVOH) polymer layer having a thickness in the range of 4μ-6μ. Thesecond ethylene vinyl alcohol (EVOH) polymer layer is in contact with asecond tie layer having a thickness in the range of 8μ-20μ. Apolyethylene layer of linear low density polyethylene (LLDPE) and lowdensity polyethylene (LDPE) having a thickness in the range of 10μ-30μin contact with the above second tie layer.

Example 9

The seven-layered ethylene vinyl alcohol (EVOH) film layer is preparedin the same way as outlined in example 8, having the laminate structure:

20μ ((Linear low density polyethylene (LLDPE)+Low density polyethylene(LDPE))//12μ Tie layer//5μ Ethylene vinyl alcohol (EVOH)//5μ Nylon 6//5μEthylene vinyl alcohol (EVOH)//12μ. Tie layer/20μ ((Linear low densitypolyethylene (LLDPE)+Low density polyethylene (LDPE)).

The total thickness of the five-layered ethylene vinyl alcohol (EVOH)film layer is 79μ.

The previously described versions of the subject matter and itsequivalent thereof have many advantages, including those which aredescribed below:

1. The present disclosure provides a partially opaque and a partiallyclear laminates of thickness of as high as 292μ that are partiallyopaque and partially clear.

2. The Plastic barrier tubes (PBL) tubes thus formed using the saidlaminate has various advantages like:

I. For packing cosmetic products pharmaceutical ointments, skin creams,toothpastes, and food materials like sauces

II. The Plastic barrier tubes (PBL) tubes come with enlarged printingbenefits as they can be printed as many as 6 colors from outside surfaceprinting.

III. They act as good gas and moisture barriers apart from their aromabarrier characteristics that are essential for preserving the flavor ofthe contents.

IV. They are made highly flexible due to the extrusion laminationprocess.

V. They are also less susceptible to cracking.

VI. These tubes possess good resilience, which eliminates the need forsecondary packaging.

VII. They are versatile in nature.

Although the subject matter has been described in considerable detailwith reference to certain preferred embodiments thereof, otherembodiments are possible. As such, the spirit and scope of the appendedclaims should not be limited to the description of the preferredembodiment contained therein. background

What is claimed:
 1. A tube or laminate tube comprising a laminate of anouter polyethylene layer wherein the outer polyethylene layer is a threelayer film comprising: 48.0%-48.5% metallocene linear low densitypolyethylene (LLDPE); 48.0%-48.5% low density polyethylene (LDPE); and3.0%-4% of a clarifier; a first adhesive layer; a substrate layer withone side selectively vacuum metalized or selectively reverse printed andsaid printed or metalized side faces toward the adhesive layer; a secondadhesive layer; and ethylene vinyl alcohol (EVOH) polymer barrier filmlayer; a low density polyethylene (LDPE) extrusion layer and an innerpolyethylene (PE) layer.
 2. A process of manufacturing the laminate tubeas claimed in claim 1, said process comprising: providing the substratelayer; selectively gravure printing or vacuum metalized to the substratelayer using a suitable ink; applying adhesive lamination on both sidesof the substrate layer; coating the substrate layer with ethylene vinylalcohol (EVOH) barrier film; coating print side of the substrate layerwith polyethylene (PE) film; extruding polyethylene (PE) film byextrusion lamination; coating the product facing side with polyethylene(PE) film; forming a partially opaque and a partially clear laminate;slitting rolls of partially opaque and a partially clear laminate byslitting process; printing of the rolls; and forming a partially opaqueand a partially clear laminated tubes by tubing process.
 3. The processas claimed in claim 2, wherein the substrate layer is selected frompolyethylene terephthalate polymer (PET), nylon, biaxially oriented film(BOPP) or Polyethylene (PE).
 4. The process as claimed in claim 2wherein the polyethylene (PE) film that forms the outer layer is surfaceprinted.